Water spray optimization and maintenance guide

Water sprays are typically used in

underground and above ground mining

operations to prevent and extinguish sparks,

disperse methane gas, knock doWn coal dust,

cool machinery and more.

Water sprays that are not performing

properly can endanger miner safety.

ensuring that Water sprays are performing

properly is extremely important.

this guide provides general recommendations

on hoW to inspect and maintain Water sprays.

it also includes selection guidelines to help

ensure the best Water sprays are being used

in various operations. hoWever, the operating

conditions in every mine are different so be

sure to contact an expert for assistance

When specifying a neW system.

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table of contents

page

InSPectIng wAteR SPRAYS 4

mAIntAInIng And RePlAcIng wAteR SPRAYS 5

when to mAke chAngeS 6

wAteR SPRAY SelectIon guIdelIneS 7

wIdelY uSed wAteR SPRAYS And AddItIonAl ReSouRceS 8

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InspectIng Water sprays

Verify that all sprays are present. Spray nozzles are small and can be accidentally damaged or broken during normal operations. Replace missing sprays immediately – even one missing spray affects system pressure and compromises the performance of the other water sprays.

Verify that all sprays are performing properly. changes in a nozzle's flow rate can be caused by many things but wear is a common reason. Flow rate changes can cause performance problems, safety concerns and wasted water.

• Examine spray patterns and watch for heavy edges and changes in spray angle or spray distribution

• Determining if the sprays are worn and spraying over capacity cannot be detected with a visual inspection. Install simple gauges to monitor system flow and pressure

inspect each spray

replace nozzles if the following conditions are observed:

• Clogging

• Corrosion

• Caking/bearding

• Damagenew

corroded

BAd SPRAY PAtteRngood SPRAY PAtteRn

erroded

new

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MaIntaInIng & replacIng Water sprays

nozzle orifices are precision engineered. Be careful to avoid damage when cleaning. use cleaning tools that are significantly softer than the material of the sprays like a toothbrush or toothpick. never clean the orifice with metal objects.

soak sprays in mild solvent to loosen debris for easier removal.

set-up a regular maintenance schedule and adhere to it. the specifics of your operation will dictate how frequently water spray inspections should occur. consider the liquid being sprayed and the quality of the water being used.

determine the optimal interval for replacement and put procedures in place to ensure it occurs.

Water sprays may look the same but may not perform the same. Be sure to replace the water sprays with the same brand. Side-by-side flow testing of water sprays from different manufacturers has revealed significant performance difference even though the published performance data is identical. Substituting brands can lead to significant fines for non-compliance with your written safety plan.

water spray nozzles that look the same may not provide the same performance. Flow rates and/or spray distribution may be quite different.

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When to Make changes

if clogging is a problem:

• Use water clarification devices

• Use strainers

• Use sprays with adequate free passage

if corrosion is a problem:

• Specify water sprays in corrosion-resistant materials

• Control water hardness level

• Use chemical additives

Be sure any changes do not violate your written safety plan.

Validate performance before making changes

If you are considering a change in your water sprays such as changing the type or brand, be sure to verify the new water sprays produce the promised performance. one mine recently decided to replace the water sprays recommended by the original equipment manufacturer with a different brand.

• Published performance data confirmed that nozzle performance should be identical

• Two sizes of each brand were tested. In the first size tested, there was no difference between the two brands

• When the second size was tested, there was a difference in flow rate. The water sprays recommended by the oem matched published data. the water sprays from the other manufacturer sprayed 24% under the rated capacity. As pressure increased, the flow rate disparity increased as well

A visual inspection of the sprays showed significant differences. the original water sprays from the oem-recommended brand were uniform and consistent. the water sprays from the other manufacturer produced a pulsating, inconsistent pattern

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are you usIng the Best Water sprays for the operatIon?

there are many types of water sprays. It is important to understand the differences in drop size and spray patterns. the following chart provides typical uses for different water sprays. however, the specifics of your operation will determine which will work best. contact an expert for assistance.

APPlIcAtIonAIR

AtomIzInghYdRAulIc FIne SPRAY

hollow cone

FlAt SPRAY

Full cone

longwall mining machines, coal shearers continuous miners

•

Jaw crushers • • •

methane gas dispersion • •

loading terminals • •

Primary dump hoppers • •

transfer points • • • •

transport areas • •

Stockpiles • •

Stackers, reclaimers • •

smallest largest drop size drop size

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WIdely used Water sprays

Spraying Systems co., the global leader in spray technology, has been serving original equipment manufacturers and mines for more than seven decades. In addition to supplying the mining industry with a wide range of water sprays and dust control equipment, the company has published several technical bulletins on drop size and dust prevention and suppression. Spraying Systems co. has consulted on the Dust Control Handbook for Industrial Minerals Mining and Processing released in January 2012 by the national Institute for occupational Safety and health (nIoSh).

for information on the products or reference material listed below, visit spray.com/miningsolutions or call 1-800-95-spray.

products

In-line and Right-Angle Bd Series whirlJet® hollow cone hydraulic nozzles

SpiralJet® hollow cone hydraulic nozzles

FloMax® Air Atomizing nozzles

J Series Air Atomizing nozzles

VeeJet® Flat Spray hydraulic nozzles

FullJet® Full cone hydraulic nozzles

ln and uniJet® hydraulic Fine Spray nozzles

literature

A guide to Spray technology for dust control, Bulletin 652

optimizing Your Spray System, technical manual 410

understanding drop Size, Bulletin 459c

the dust control handbook from nIoSh is available online: spray.com/miningsolutions

North Avenue and Schmale Road, P.O. Box 7900, Wheaton, IL 60187-7901 USA

tel: 1.800.95.SPRAY Intl. tel: 1.630.665.5000 Fax: 1.888.95.SPRAY Intl. Fax: 1.630.260.0842

www.spray.com

Bulletin no. 697 Printed in the u.S.A. ©Spraying Systems co. 2012

A Guide to Spray Technology for Dust Control

Spray Nozzles

Spray Control

Spray Analysis

Spray Fabrication